KGCOE MSD Technical Review Agenda WOCCS System Level Detailed Design Review

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1 KGCOE MSD Technical Review Agenda WOCCS System Level Detailed Design Review Review Agenda Meeting Purpose: 1. Evaluate Design 2. Compare to Engineering Specifications and Risk Assessment Materials to be Reviewed: 1. Mission Profile 2. Revised Engineering Specifications. Interface Specification Detailed 4. Detailed Drawings Subsystem and Entire System 5. Initial Test Plan. Bill of Materials & Preliminary Budget Analysis 7. Failure Mode & Effective Analysis (FMEA) 8. Revised Risk Assessment 9. Project Plan Meeting Date: November 5, 2010 Meeting Location: Bldg. 09 Room 445 Meeting time: 8:00AM 10:00AM Timeline: Meeting Timeline Start time Topic of Review Required Attendees 8:00 8:10 Review Mission Profile Phil Bryan, Leo Farnand, Dr. Hensel 8:10 8:20 Revised Engineering Needs & Specs Phil Bryan, Leo Farnand, Dr. Hensel -Calculations 8:20 8:0 Bill of Materials Phil Bryan, Leo Farnand, Dr. Hensel 8:0 8:5 Questions, Concerns, Risks Phil Bryan, Leo Farnand, Dr. Hensel 8:5 9:00 Interface Specifications -D Model -Interface Document -Drawing Schematics Phil Bryan, Leo Farnand, Dr. Hensel 9:00-9:10 Questions, Concerns, Risks Phil Bryan, Leo Farnand, Dr. Hensel 9:10 9:25 FMEA Phil Bryan, Leo Farnand, Dr. Hensel 9:25 9:0 Questions, Concerns, Risks Phil Bryan, Leo Farnand, Dr. Hensel 9:0 9:40 Initial Test Plan Phil Bryan, Leo Farnand, Dr. Hensel 9:40 9:45 Detailed Design Risks Phil Bryan, Leo Farnand, Dr. Hensel 9:45 9:50 Project Plan Phil Bryan, Leo Farnand, Dr. Hensel 9:50 10:00 Questions, Concerns, Risks Phil Bryan, Leo Farnand, Dr. Hensel WOCCS Detailed Design Review Page 1

2 Mission Statement Mission Profile - WOCCS Team The WOCCS System is designed to wirelessly transmit command data from a base station to a remote unit at both a mid and long range distance. The remote unit receives the command, perform the function, and collect telemetry data via USB to transmit back to the base station PC. Duty Cycles of RF One usage of the WOCCS unit includes powering on unit, attaching to remote unit, and transmitting/receiving up to 5 kbps of command and telemetry data for the maximum time usage of 2 hours, powering off unit, and leaving it in idle state for recharge for 2 hours. Duty Cycles Typical Mission Marginal Test Limit Target Test Limit Typical Mission Length 10 minutes 0-15 minutes 0-0 min Maximum Mission Length 0 minutes 1.5 hours 2 hours # Usage Times / Day (in succession) 1 (10 min use) 2 (2 hour use) (2 hour use) TX % 15% 12.5% 15% RX % 15% 12.5% 15% % in Idle 70% 75% 70% Recharge Time N/A hours 2 hours *Typical Mission will not need batteries recharged. Recharging occurs after 2 hours of use Data Transfer The WOCCS System is primarily transmitting and receiving simplistic command data to control the LV One Platform. Commands may include moving the robot forward, backward, or directional. The WOCCS System will also be able to collect basic telemetry data such as temperature and relative humidity from the remote unit and transmit data back to base station. Engineering Specifications Typical Mission Marginal Target Bandwidth 5 kbps 4 kbps 5 kbps Range (MidRange) 100 meters meters meters Range (LongRange) 1000 meters m m Error Loss (Bit Error Rate) 0.12% 0.12% 0% Latency sec 1 sec 0.2 sec Mid-Range Environment Conditions The WOCCS Unit will be primarily used in indoor conditions, specifically in the SLC field house. The surface the unit will attach to will primarily be the LV One Platform. This robot is used in design competitions demonstrating the robots ability to interpret control signals and return telemetry data to a base unit. The robot will be operating on hard, flat surface such as tile, a mat, or track. WOCCS Detailed Design Review Page 2

3 Environmental Conditions Typical Mission Marginal Target External Operating Temp 5-70 F F 0-95 F Precipitation None None None Wind speed 0-5mph 0-10 mph 0-25 mph Snow Not permittable Not permittable Not permittable Relative Humidity 0-50% 0-85% 0-95% Maximum Surface Incline Long Range Environmental Conditions The long range team will be using the robot in outside conditioned, permitting weather conditions are ideal. A typical mission consists of transmitting and receiving the same data as the mid-range in an external temperature such as RIT s parking lot. Ideal weather conditions include lack of precipitation, snow, storms, lightening, or outside all environment ranges specified below. Environmental Conditions Typical Mission Marginal Target External Operating Temp F 0-90 F F Precipitation (Consistent Rain) No No No Wind speed 5-12mph 0-15 mph 0-0 mph Snow Not permittable Not permittable Not permittable Relative Humidity 0-0% 0-85% 0-95% Maximum Surface Incline Physical Obstructions WOCCS will be attachable to the LV One Platform. Physical obstructions include the motor controller, wheels, external base, and circuitry the robot uses. During the senior design mission, obstacles may include walls, bumps in ground (not exceeding 1 inch), and other walled structures that the competition may include. The WOCCS unit will be designed to transmit and receive signals in a room or outside environment that is assumed to have little or no frequency interference caused by obstacles. Physical Obstructions Typical Mission Marginal Target Cell Phone Interference Possible Possible Possible Other Competition Units Interference Possible Possible Possible Walls - Interference Surface Variation 0-1 inch 0-2 inch 0- inch Antenna Testing Orientation Vertical bends 90 Vertical Vertical *Interference mediums will be determined based on the FCC Medium Interference Regulations. Multiple units will be able to operate using the same frequency. *Possible Obstructions may include but are limited to: walls, chairs, tables, people, boxes, SLC equipment used during display set-ups. WOCCS Detailed Design Review Page

4 Customer Needs Customer Need # CN#1 CN#2 CN# CN#4 CN#5 CN# CN#7 CN#8 Importance Description System must transmit command data from base to remote unit System must communicate status and sensor data between base and remote units System must be powered by portable high power density energy system System can be easily programmed to allow debugging and development testing System will be portable (both base station and remote platform) System must have modular design System must be reliable System must have operator friendly design Ownership P11207, P11208, P11209 P11207, P11208, P11209 P11401 P11210 P11204 All All All Engineering Specs ES # Importance Spec Range of Signal Units Marginal Target Mid Range 1 Mid Range 2 Long Range Data Rate * Error Loss (Bit Error Rate)* Latency Operating Time Recharge Time Size (L x W x H) meters meters meters kbps % ms hours hours Entire Unit cm kg 12x14x 10x1x (288 cubic cm) (780 cubic cm) Weight 10 Entire Unit Battery Changeover Time Board Changeover Time Mid range Specs Internal Operating Temp External Operating Temp Relative Humidity Long range Specs Internal Operating Temp External Operating Temp Relative Humidity Shock/Vibe Lifespan Drop Test Unit Assembly Time minutes minutes 2 ( 4 lbs) (.5 lbs) ⁰C ⁰F % ⁰C ⁰F % G's / ms Cycles meters Minutes Gs / 10 ms 100, Gs / 10 ms 1,000, CN # Description CN#1 System must transmit command data from base to remote unit System must communicate status and sensor data between base and remote Powered by High Density CN# Battery System CN#2 CN#5 System will be portable (both base station and remote platform) CN# System must have modular design CN#7 System must be reliable CN#8 Operator Friendly Design Functionality - Specs Able to configure to PC? Li-On Battery Used? Be able to be tested for: Power Usage Bit Error Rate Latency Range Bandwidth Interchangeable RF Modules? Modular Battery? Easy to supply power to boards? Modular Antenna used? FCC Approved? External accessible Inputs? Power Status displayed? Status of Transfer displayed? Easily configured antenna? Easy to assemble? WOCCS Detailed Design Review CN#2 Transmit command data CN# High Density Battery System System can be easily CN #4 programmed to allow debugging and development testing CN# System must have modular design CN#7 System must be reliable CN#8 Operator Friendly Design Page 4

5 Longitude Elevation Speed Acceleration Facing (N/S/E/W) Data-Rate Calculations (Revised) Vertical Tilt RF Signal Strength Data To Be Sent Size of Data Battery Voltage Mission Status Status Data 54 bytes Vehicle Status (Flaps Up/Down, Jets 5%, etc.) Latitude 8 bytes Operating System Status (Controller State, Errors, etc.) Longitude 8 bytes High Quality Sensor Data Elevation 8 bytes Temperature Data Speed 2 bytes Pressure Data Acceleration 2 bytes Atmosphere Data Facing (N/S/E/W) 2 bytes Other Data Vertical Tilt 2 bytes RF Signal Strength 2 bytes Initial Total Battery Voltage 2 bytes Marginal Calcuations Mission Status 2 bytes Final Total = Initial*4(We want a 4x Capacity) 400 Bytes Vehicle Status (Flaps Up/Down, Jets 5%, etc.) 8 bytes*this assumes we send data once originally, it fails, it needs to send data back, and then attempt to transmit Bandwidth Operating = System Total Bytes Status * 8 (Controller bits/byte State, Errors, etc.) 200 bps 8 bytes data again High Quality Sensor Data /8 bits 4 / byte bytes Kilobits Temperature / second Data 4 kbps8 bytesmarginal Pressure Data 8 bytes Target Calculations Atmosphere Data 1 bytes Assume 2 bytes of data tranferred for telemetry 2 bytes Other Data 14 bytes Assume data transferred at least 200 times / second 200 times per second 400 bytes / second 8 bits / byte bits per second Initial Total 100 Bytes 1000 bits / kilobit 51.2 kilobits / second *Standard for RS22 and USB comes in 5 kbps so this is final target value Kilobits / second 5 kbps Target 8 bytes 8 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 8 bytes 8 bytes 4 bytes 8 bytes 8 bytes 1 bytes 14 bytes 100 Bytes Error Rate Calculations Maximum Baud Rate will not exceed bps, therefore a average Error % was chosen from commonly used 2 MHz: 12% Marginal 0% Target Source: Latency Calculations Average Command Data 100 bytes Total Latency seconds Average Telemetry Data 200 bytes Marginal Latency 1000 ms Data Rate 5 kbps Target Latency 200 ms Command Latency seconds Telemetry Latency seconds WOCCS Detailed Design Review Page 5

Preliminary Bill of Materials for WOCCS Family Preliminary Bill of Materials for WOCCS Family Team Price/1 unit # needed for MSD II Price/8 boards Overhead costs Total for MSD P11204 - Housing Team

6 Preliminary Bill of Materials for WOCCS Family Preliminary Bill of Materials for WOCCS Family Team Price/1 unit # needed for MSD II Price/8 boards Overhead costs Total for MSD P Housing Team $ $20.00 $0.00 $20.00 P Mid-Range 1 RF Board $ $1.5 $17.40 $ P Mid-Range 2 RF Board $1.7 8 $ $ $9.08 P Long-Range RF Board $4.4 8 $71.47 $ $9.47 P RF Test Bench $ $ $0.00 $ P Portable High Powered Density Energy System $ $25.78 $ $5.78 P Power conversion for charging $ $21.81 $0.00 $21.81 P Mechanical (Turbine) $2.1 1 $2.1 $0.00 $2.1 Grand Total $, Common components WOCCS Detailed Design Review Page

7 Systems View of Entire Unit Closed View Side View Exploded View WOCCS Detailed Design Review Page 7

Interface Document Battery to Power Electronics System 1 System 2 Subsystem Units WOCCS Values Comments http://www.batteryspace.

8 Interface Document Battery to Power Electronics System 1 System 2 Subsystem Units WOCCS Values Comments Type 1850 Battery Holder holder-li-ion-1850-battery-holder-1s1p- with-2.-long-20awg.aspx Overcharge > 4.2 V Protect battery from max volt Battery Battery to Power Electrical Over discharge < 2.5 V Protect battery from max volt Electronics Over drain >.0 Amp Protect battery from max amp Connector Type Soldered to Board Connector location 4.94, 5.0 mm from bottom left corner See Drawing #A, B, C Size 80 x 21 x 18.0 mm See Drawing #D - Picture Wire gauge 22 # Dependant upon maximum current; A Top View Power Electronics 1 B Side View Power Electronics 12 C D 1 All dimension tolerance +/ mm 2 Battery may protrude from holder - Limited height clearance of 10.5 mm until housing top WOCCS Detailed Design Review Page 8

49 mm See Drawing #7A Connector Male/Female Plug is a barrel plug Connector location 28.

9 Power Electronics PE to On/Off Switch PE to Charging Dock PE to Test Bench PE to RF Module Voltage 8.4 volts Operating Range of components Current 2 amps Max current drawn by the RF link Electrical Size x 10.2 x 7.49 mm See Drawing #7A Connector Male/Female Plug is a barrel plug Connector location 28.4, 0 mm from bottom left corner See Drawing #A Wire gauge 22 # Dependant upon maximum current Type PJ-047A Voltage 2.5A Maximum Volts drawn from RF link Contact Resistance 50m Ω MAX Maximum Resistance from Contact Electrical Insulation Resistance 500V AC RMS for 1 minute Maximum Resistance from Insulation Size 11.7 x 11.5 x 7mm (2mm Diameter) See Drawing #7B Connector Barrel Connector See Picture #7B Connector location 59.7, 0.0 mm from bottom corner See Drawing #A Voltage 8.4 volts Maximum Volts drawn from RF link Current 2 amps Maximum Current from RF Link Electrical Size 12.8 x 9. x 1.2 mm See Drawing #7C Connector WM2821-ND See Picture #7C Connector location 0, 12mm from top right of board See Drawing #A Voltage 00 Volts Maximum Volts drawn from RF link Electrical Current 1 A Max current drawn by the RF link PE Connector Wire solder to bottom of board Permanent Connection - Bottom on PE Wire gauge 18 AWG Dependant upon maximum current 7A On/Off Switch 7B Charging Dock WOCCS Detailed Design Review Page 9

27 mm 2 Power consumption test will require unit to remain open for access

10 7C Test Bench Connector 2 System View of Power Electronics 1 1 Dimension tolerance +/ mm 2 Power consumption test will require unit to remain open for access to Power Electronics. Functional testing will be performed through USB Port while unit it closed. WOCCS Detailed Design Review Page 10

RF Modules RF Module to PE RF Mod to USB Port RF Mod to LED Lights RF Mod to Antenna Electrical Electrical Electrical Electrical Voltage 00 Volts Maximum Volts drawn from RF link Current 1 A Max

11 RF Modules RF Module to PE RF Mod to USB Port RF Mod to LED Lights RF Mod to Antenna Electrical Electrical Electrical Electrical Voltage 00 Volts Maximum Volts drawn from RF link Current 1 A Max current drawn by the RF link RF Connector 4.20mm (.15") Pitch Mini-Fit Jr. See Drawing #5 for Specs Connector location 0, 12 mm from top right of board See Drawing # Wire gauge 18 AWG Dependant upon maximum current Type Tyco (Type B Female Right-Angle) Connector Solder Standard Size 15.7 x 12.0 x mm See Drawing #4 A - Spec Sheet Location 10 mm from Left Edge See Drawing # Type Dialight F 4 Green LED Horizontal Bank Connector Solder Size 7.11 x.5 x 17.27mm See Drawing #4 C Spec Sheet Location mm from USB, 7.7 from RF See Drawing # Type Connector City CONREVSMA002 RP-SMA Female Right-Angle Antenna Type Omni Directional Size 7 x 15.2 x 1.9 mm See Drawing #4 B - Spec Sheet Location 10 mm from Right Edge See Drawing # #5 RF Connector to Power Electronics *Two Pin Connector is being used #4A RF Module to USB Port WOCCS Detailed Design Review Page 11

12 #4 B - RF Module to Antenna #4 C - RF Module to LED Lights WOCCS Detailed Design Review Page 12

13 External Environment # System View of RF Boards 1 1 Dimension tolerance +/ mm Housing Housing Top to LV1 Mount Bolt pattern Philips Head # Bolts Needed = 4 Bolt size M5 Location 4 Screws on bottom of extrusion Layout TBD Based on LV1 Application See Drawing #1 * Mounting to the LV1 will be analyzed after unit is built completely to allow for modular attachment techniques Aluminum Extrusion Base with screws attached to end flaps WOCCS Detailed Design Review Page 1

14 Housing Connections RF Mod to Housing Housing to PE Mounting Card Housing Top to Extrusion 2A Side Profile 1 Mount Mount Mount Connector Slots in extrusion Board Length 90mm Board Width 70mm See Drawing # 2A Board Height 1.58mm Layout Slot # From Bottom Type Slots in extrusion The connectors are located on the PCB Location Slot #11 See Drawing #2A Size Mounting Card - 2 mm thick Bolt pattern Philips Head # Bolts Needed = 4 Bolt size M5 Location 2.77 inches bottom to top hole See Drawing # 2B Layout 4 Screws-each corner of Housing Top See Drawing # Slide Plate Holes: Housing to On/Off Switch Size/Location 29.4, mm from bottom left Housing to Charge Location Size/Location 0, mm from bottom left Mount Housing to RF LEDs Size/Location 0.8, mm from bottom left Housing to Antenna Size/Location 5.7, mm from bottom left Housing to USB Size/Location 10.7, mm from bottom left See Drawing #2B 2B End Plate Dimensions 1 1 Dimension tolerance +/ mm WOCCS Detailed Design Review Page 14

15 Failure Modes and Effects Analysis WOCCS Detailed Design Review Page 15

16 WOCCS Detailed Design Review Page 1

17 P11204 System Level Initial Test Plan Project Overview WOCCS family of projects is a continuation of the LV-1 Wireless Command and Control System project. Off the shelf transceiver units were implemented to send user input commands to the LV-1 and receiver sensor data information about the robot. The mission of this project is to design and build a housing for the Digital Baseband and RF modules that will be integrated into a wireless open-source/open-architecture command and control system (WOCCS). Key Deliverables - Functional base unit transmitting command data, interface to PC. - Functional receiver unit receiving command data, transmitting sensory data back to base. - Documentation and User Guide Manual Team Members: Amy Powell Dustin Falkner Guide: Phil Bryan, Leo Farnand, Vince Burolla Customer: Dr. Hensel and Harris Test Strategy Source Specification (description) Unit of Measure Marginal Value Ideal Value Test Method Data Type Current Design Capability Status ES #1 Range of Signal for Mid-Range Meters Test Bench Length in meters Proper mission testing ES #2 Range of Signal for Long-Range Meters Test Bench Length in meters Proper mission testing ES # Able to transmit data? - Test Bench or No Proper mission testing ES #4 Data Rate kbps 4 5 Test Bench Rate in kbps Proper mission testing WOCCS Detailed Design Review Page 17

18 ES #5 Error Loss (bit error rate) % Data Loss Test Bench pber Proper mission testing ES # Latency ms Test Bench Measure d in ms Proper mission testing Time trials Time in hours Battery capacity allows operation at maximum current draw for greater than 2 hours Wind Turbine otherwise outlet powered ES #7 ES #8 Operating Time Recharge Time hours hours Time trials Time in hours cm 12x14x (288 cubic cm) 10x1x (780 cubic cm) Measure dimensions Size in cm Total size is less than 780 cubic cm 1. (.5 lbs.) Measure weight Mass in kg Total material mass does not exceed.5 lbs. ES #9 Size of Entire Unit ES #10 Weight of Entire Unit kg 2 ( 4 lbs.) ES #11 Battery Changeover Time minutes 5 Time Assembly Time in minutes Battery can be assembled with minimal effort ES #12 Board Changeover Time minutes 5 Time Assembly Time in minutes Boards can be assembled with minimal effort Temp. in ⁰C All components and materials are specified to operate over this temperature range Temp in ⁰F All components and materials are specified to operate over this temperature range ES #1 ES #14 Mid-Range Internal Operating Temp Mid-Range External Operating Temp ⁰C ⁰F WOCCS Detailed Design Review Thermal analysis Thermomet er Page 18

19 ES #15 Mid-Range Relative Humidity ES #1 Long-Range Internal Operating Temp % ⁰C Weather Report Thermal Analysis Measure d in % Mission profile specs must be considered Temp. in ⁰C All components and materials are specified to operate over this temperature range ES #17 Long-Range External Operating Temp ⁰F Thermomet er Temp in ⁰F All components and materials are specified to operate over this temperature range ES #18 Long-Range Relative Humidity % Weather report Measure d in % Mission profile specs must be considered 5 Gs / 10 ms ESS / Vibe Test Measure d in G s / ms All materials are durable ES #19 Shock/Vibe G's / ms 5 Gs / 10 ms ES #20 Lifespan Cycles 100,000 1,000,000 Use durability of materials Number of cycles Repeated use ES #21 Drop Test meters 1 2 Use durability of materials Length in meters Housing materials are durable ES #22 Unit Assembly Time Minutes 10 5 Time Trials Minutes Proper mission testing WOCCS Detailed Design Review Page 19

20 Functionality Test ES #2 Able to configure to PC? - Direct connect or No USB connection ES #24 Li-On Battery Used? - Power Team or No Li-on battery fits within battery holder ES #25 Power Consumption - Test Bench or No Battery specs ES #2 Bit Error Rate - Test Bench or No ES #27 Latency - Test Bench or No ES #28 Range - Test Bench or No ES #29 Bandwidth - Test Bench or No System can be easily programmed System can be easily programmed System can be easily programmed System can be easily programmed ES #0 Interchangeable RF Modules? - Base off of Assembly time or No RF Modules can be assembled with minimal effort ES #1 Modular Battery? - Base off of Assembly time or No Battery is not tethered to any external source ES #2 Easy to supply power to boards? - Base off Unit Assembly Time or No Durable and Reliable wires will be used ES # Modular Antenna used? - Observe or No Detachable antenna will be used WOCCS Detailed Design Review Page 20

21 ES #4 FCC Approved? - Refer to document or No Designed due to FCC Regulations ES #5 External accessible Inputs? - Observe or No All inputs will be easily assessable protruding through housing ES # Power Status displayed? - Observe or No LED lights will be connected within housing and easily accessible ES #7 Status of Transfer displayed? - Observe or No LED lights will be connected within housing and easily accessible ES #8 Easily configured antenna? - Base off of Assembly time or No Antenna can be assembled with minimal effort ES #9 Easy to assemble? - Base off of Assembly time or No All components can be assembled with minimal effort WOCCS Detailed Design Review Page 21

22 Revised Risk Assessment WOCCS Detailed Design Review Page 22

23 Project Planning WOCCS Detailed Design Review Page 2

24 Detailed Design Action Items Action Item # Action Description Owner Due Date 1 Updated all connectors / specs / pictures Amy 11//2010 Additional Notes WOCCS Detailed Design Review Page 24

Wireless Open-Source Open Controlled Command and Control System WOCCS Design Project. User Manual

MSD - 2011 Rochester Institute of Technology Wireless Open-Source Open Controlled Command and Control System WOCCS Design Project User Manual Revision 1 P11204 Systems Level User Manual WOCCS User Manual